Laundry treating appliance with tub and structural support

ABSTRACT

A laundry treating appliance for treating laundry according to an automatic cycle of operation and including a cabinet defining an interior, an imperforate tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base, and a structural support provided within the interior adjacent at least a portion of the imperforate tub.

BACKGROUND OF THE INVENTION

Laundry treating appliances, such as a washing machine, are known to have a configuration where a rotating basket is provided within a tub and the basket defines a treating chamber in which laundry is placed for treatment. The laundry treating appliance may have a controller that implements a number of user-selectable, pre-programmed cycles of operation. Hot water, cold water, or a mixture thereof along with various treating chemistries is supplied to the treating chamber in accordance with the cycle of operation. A common consideration in design of such laundry treating appliances is increasing capacity; however, a variety of factors must be considered in doing so.

SUMMARY OF THE INVENTION

In one aspect, illustrative embodiments in accordance with the present disclosure relate to a laundry treating appliance for treating laundry according to an automatic cycle of operation, comprising a cabinet defining an interior, an imperforate tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base, a structural support provided within the interior under at least a portion of the imperforate tub, and a suspension mounting the structural support to the cabinet.

In another aspect, illustrative embodiments in accordance with the present disclosure relate to a laundry treating appliance for treating laundry according to an automatic cycle of operation, comprising a cabinet defining an interior, an imperforate tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base, a structural support provided within the interior beneath the imperforate tub, and a suspension system coupling the structural support to the cabinet, and wherein at least a portion of the base of the imperforate tub is formed from a flexible material and such flexible portion is configured to move downwards under a weight of liquid located therein to bear against the structural support.

In yet another aspect, illustrative embodiments in accordance with the present disclosure relate to a laundry treating appliance for treating laundry according to an automatic cycle of operation, comprising a cabinet defining an interior; and an imperforate tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base and a structural support separate from the imperforate tub and provided within the interior adjacent a base of the imperforate tub and where the structural support is mounted to the cabinet via a suspension system.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a partially schematic cross-sectional view of a laundry treating appliance according to an illustrative embodiment in accordance with the present disclosure.

FIG. 2 is a schematic representation of a controller for controlling the operation of one or more components of the laundry treating appliance of FIG. 1.

FIG. 3 is a perspective view of a structural support of FIG. 1.

FIG. 4 is a cross-sectional view of portions of the laundry treating appliance of FIG. 1.

FIG. 5 is a partially schematic cross-sectional view of a laundry treating appliance showing an alternative tub and suspension system.

FIG. 6 is a perspective view of an alternative structural support that can be utilized in the appliances of FIG. 1 and FIG. 5.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Typically the tub provides both liquid containment and structural functions. Both functions of the tub limit the capacity of the laundry treating appliance. Embodiments in accordance with the present disclosure relate to the use of a structural support, which splits these functions and shifts the structural function away from the tub. This allows for many benefits, including reduced noise and less vibration transmitted to the housing as well as the ability to have an increased capacity in the tub.

FIG. 1 illustrates a laundry treating appliance in the form of a washing machine 10 according to an illustrative embodiment in accordance with the present disclosure. The laundry treating appliance is any machine that treats articles such as clothing or fabrics. Non-limiting examples of the laundry treating appliance may include a vertical washing machine; a combination washing machine and dryer; and a refreshing/revitalizing machine. The washing machine 10 described herein shares many features of a traditional automatic washing machine, which will not be described in detail except as necessary for a complete understanding of illustrative embodiments in accordance with the present disclosure.

Washing machines are typically categorized as either a vertical axis washing machine or a horizontal axis washing machine. As used herein, the “vertical axis” washing machine refers to a washing machine having a rotatable drum, perforate or imperforate, that holds fabric items and a clothes mover, such as an agitator, impeller, nutator, and the like within the drum. The clothes mover moves within the drum to impart mechanical energy directly to the clothes or indirectly through wash liquid in the drum. The clothes mover may typically be moved in a reciprocating rotational movement. In some vertical axis washing machines, the drum rotates about a vertical axis generally perpendicular to a surface that supports the washing machine. However, the rotational axis need not be vertical. The drum may rotate about an axis inclined relative to the vertical axis. As used herein, the “horizontal axis” washing machine refers to a washing machine having a rotatable drum, perforated or imperforate, that holds fabric items and washes the fabric items by the fabric items rubbing against one another as the drum rotates. In some horizontal axis washing machines, the drum rotates about a horizontal axis generally parallel to a surface that supports the washing machine. However, the rotational axis need not be horizontal. The drum may rotate about an axis inclined relative to the horizontal axis. In horizontal axis washing machines, the clothes are lifted by the rotating drum and then fall in response to gravity to form a tumbling action. Mechanical energy is imparted to the clothes by the tumbling action formed by the repeated lifting and dropping of the clothes. Vertical axis and horizontal axis machines are best differentiated by the manner in which they impart mechanical energy to the fabric articles. The illustrated exemplary washing machine of FIG. 1 is a vertical axis washing machine.

As illustrated in FIG. 1, the laundry treating appliance 10 may include a housing 14 defining an interior 16. The housing 14 can be a cabinet or a frame to which decorative panels may or may not be mounted. A user interface 18 is included on the housing 14 and may have one or more knobs, switches, displays, and the like for communicating with the user, such as to receive input and provide output. A door or lid 20 is operably coupled with the housing 14 and is selectively moveable between opened and closed positions to close an opening in a top wall of the housing 14, which provides access to the interior 16 of the housing 14.

A rotatable drum 22 having an open top is disposed within the interior of the housing 14 and may define a treating chamber 24 for treating laundry. An imperforate tub 26 may also be positioned within the interior 16 of the housing 14 and may define an interior within which the drum 22 is positioned. The drum 22 may include a plurality of perforations (not shown), such that liquid may flow between the tub 26 and the drum 22 through the perforations. While the illustrated washing machine 10 includes both the tub 26 and the drum 22, with the drum 22 defining the laundry treatment chamber 24, it is within the scope of the present disclosure for the laundry treating appliance to include only one receptacle, with the receptacle defining the laundry treatment chamber for receiving the load to be treated and the tub.

The imperforate tub 26 is illustrated as including a peripheral wall 28 with an upper portion 30 and a bottom end 32 closed by a base 34. Unlike contemporary tubs, the tub 26 can be free of ribbing and otherwise does not include structural reinforcements, or includes less ribbing and/or structural reinforcements as compared to contemporary tubs. In contemporary tubs there is typically ribbing or other measures for structural rigidity. The elimination or reduction of the ribbing and structural reinforcements reduces the weight of the tub 26. A structural support 80 separate from the tub 26 is included within the washing machine 10 and may provide at least some of the structural function that has been removed from the tub 26.

With the removal of the structural reinforcements, the tub 26 can be considered to be less rigid or more flexible than contemporary tubs. Further, at least a portion of the imperforate tub 26 can be formed from a flexible material. For example, at least a portion of the base 34 may be formed from a flexible material and may define a flexible portion. In such implementations, the flexible portion of the base 34 can move downwards under a weight of liquid located therein to bear against the structural support 80 when liquid is located within the tub 26. In exemplary implementations, the flexible material of the base 34 may have a similar flexibility to the sidewall or upper parts of the tub 26.

The structural support 80 can frame at least a portion of the tub 26 including at least a portion of the base 34. While the structural support 80 is illustrated as being below the entire base 34 of the tub 26 it is contemplated that the structural support 80 can be provided within the interior 16 under only a portion of the imperforate tub 26.

A suspension system 36 is provided within the interior 16 and mounts the structural support 80 to the housing 14. In this manner, when the tub 26 bears against the structural support 80 it is also supported by the suspension system 36. The suspension system 36 dampens the vibrations generated during the rotational movement of the rotatable drum 22. The suspension system 36 is illustrated as including a plurality of suspension rods 37 and may include any suitable springs, damping mechanisms, etc.

A clothes mover 38 is located in the drum 22 to impart mechanical agitation to a load of laundry placed in the drum 22. The drum 22 and the clothes mover 38 are driven by a drive system that includes an electrical motor 40 operably coupled with the drum 22 and clothes mover 38. A clutch assembly 41 is included in the drive system and is provided to selectively operably couple the motor 40 with either the drum 22 and/or the clothes mover 38. The clothes mover 38 is oscillated or rotated about its axis of rotation during a cycle of operation in order to produce high water turbulence effective to wash the load contained within the treating chamber 24. The motor 40 may rotate or oscillate the drum 22 at various speeds in either rotational direction about an axis of rotation.

A liquid supply system is provided to supply liquid, such as water or a combination of water and one or more wash aids, such as detergent, into the treating chamber 24. The liquid supply system may include a water supply configured to supply hot or cold water. The water supply may include a hot water inlet 44 and a cold water inlet 46, a valve assembly, which may include a hot water valve 48, a cold water valve 50, and a diverter valve 55, and various conduits 52, 56, 58. The valves 48, 50 are selectively openable to provide water, such as from a household water supply (not shown) to the conduit 52. The valves 48 and 50 can be opened individually or together to provide a mix of hot and cold water at a selected temperature. While the valves 48, 50 and conduit 52 are illustrated exteriorly of the housing 14, it is understood that these components can be internal to the housing 14.

As illustrated, a detergent dispenser 54 is fluidly coupled with the conduit 52 through a diverter valve 55 and a first water conduit 56. The detergent dispenser 54 may include means for supplying or mixing detergent to or with water from the first water conduit 56 and may supply such treating liquid to the tub 26. It has been contemplated that water from the first water conduit 56 may also be supplied to the tub 26 through the detergent dispenser 54 without the addition of a detergent. A second water conduit, illustrated as a separate water inlet 58, may also be fluidly coupled with the conduit 52 through the diverter valve 55 such that water is supplied directly to the treating chamber through the open top of the drum 22. Additionally, the liquid supply system may differ from the configuration shown, such as by inclusion of other valves, conduits, wash aid dispensers, heaters, sensors, such as liquid level sensors and temperature sensors, and the like, to control the flow of treating liquid through the washing machine 10 and for the introduction of more than one type of detergent/wash aid.

A liquid recirculation system is provided for recirculating liquid from the tub 26 into the treating chamber 24. More specifically, a sump 60 is located in the bottom of the tub 26 and the liquid recirculation system is configured to recirculate treating liquid from the sump 60 onto the top of a laundry load located in the treating chamber 24. A pump 62 is housed below the tub 26 and may have an inlet fluidly coupled with the sump 60 and an outlet configured to fluidly couple to either or both a household drain 64 or a recirculation conduit 66. In this configuration, the pump 62 is used to drain or recirculate wash liquid in the sump 60. As illustrated, the recirculation conduit 66 is fluidly coupled with the treating chamber 24 such that it supplies liquid into the open top of the drum 22. The liquid recirculation system may include other types of recirculation systems.

The washing machine 10 may further include a controller 70 coupled with various working components of the washing machine 10 to control the operation of the working components. As illustrated in FIG. 2, the controller 70 is provided with a memory 72 and a central processing unit (CPU) 74. The memory 72 is used for storing the control software that is executed by the CPU 74 in completing a cycle of operation using the washing machine 10 and any additional software. The memory 72 may also be used to store information, such as a database or table, and to store data received from the one or more components of the washing machine 10 that is communicably coupled with the controller 70.

The controller 70 is operably coupled with one or more components of the washing machine 10 for communicating with and/or controlling the operation of the components to complete a cycle of operation. For example, the controller 70 is coupled with the hot water valve 48, the cold water valve 50, diverter valve 55, and the detergent dispenser 54 for controlling the temperature and flow rate of treating liquid into the treating chamber 24; the pump 62 for controlling the amount of treating liquid in the treating chamber 24 or sump 60; the motor 40 and clutch 41 for controlling the direction and speed of rotation of the drum 22 and/or the clothes mover 38; and the user interface 18 for receiving user selected inputs and communicating information to the user. The controller 70 may also receive input from a temperature sensor 76, such as a thermistor, which may detect the temperature of the treating liquid in the treating chamber 24 and/or the temperature of the treating liquid being supplied to the treating chamber 24. The controller 70 may also receive input from various additional sensors 78, which are known in the art and not shown for simplicity. Non-limiting examples of additional sensors 78 that is communicably coupled with the controller 70 include: a weight sensor, and a motor torque sensor.

The washing machine 10 can perform one or more manual or automatic treating cycles or cycle of operation. A common cycle of operation includes a wash phase, a rinse phase, and a spin extraction phase. Other phases for cycles of operation include, but are not limited to, intermediate extraction phases, such as between the wash and rinse phases, and a pre-wash phase preceding the wash phase, and some cycles of operation include only a select one or more of these exemplary phases.

During operation, the drum 22 and the structural support 80 are coupled via components associated with the drive system. As such, movement of the drum 22 may cause corresponding movement of the structural support 80. However, because the drum 22 and the structural support 80 are decoupled from the tub 26, vibrations of the drum 22 and corresponding vibrations of the structural support 80 are not transmitted to the tub 26, which reduces noise and vibration effects. Likewise, in implementations where the tub 26 is in physical contact with the housing 14, noise and vibration is similarly prevented from being transmitted to the housing 14. Further, because a flexible portion is included in the tub 26, it can move downwards under a weight of liquid located therein to bear against the structural support 80 and be braced thereby. The flexible portion of the tub may further help to isolate other portions of the tub from vibration of the drum 22 and/or structural support 80.

FIG. 3 illustrates exemplary structural support 80 more clearly and it may more easily be seen that the structural support 80 includes a base 82 and set of arms 84. The base 82 can be formed in any suitable manner including that it can be shaped to accommodate portions of the drive system. In the exemplary illustration, the base 82 includes an opening that accommodates the clutch 41 passing through the base 82. It will be understood that “a set” can include any number of arms, including only one arm. While this need not be the case, in the illustrated example, the structural support includes a set having four arms 84. The arms 84 can be mounted to the base 82 in any suitable manner including, but not limited to, via fasteners or via spot welds or some other “fastener-less” process. Alternatively, the arms 84 and the base 82 can be integrally formed with each other. In the illustrated example, each arm 84 includes a lower portion 86 that can be mounted to the base 82 via fasteners and an upper portion 88, which can be operably coupled to a portion of the suspension system 36. As illustrated, the suspension system 36 can mount each of the four arms 84 to a separate corner of the housing 14.

FIG. 4 is a cross-sectional view of portions of the laundry treating appliance of FIG. 1 and more clearly illustrates the portion of the base 34 in a retracted position (A) when the tub 26 is empty and where the base 34 does not bear on the structural support 80. An expanded position (B) that occurs when the tub 26 contains liquid is illustrated in phantom. In the expanded position B the base 34 is below the retracted position A.

FIG. 4 further illustrates that the tub 26 can be formed from multiple materials. For example, a portion 35 of the base 34, which is mounted to the structural support 80, is illustrated as being formed from a first material and an other portion 33 of the base 34 is illustrated as being formed from a second material. The portion 35 may be formed of a more rigid material than the other portion 33. For example, the portion 35 can be formed from polypropylene or aluminum. The portion 35 has been illustrated as a central portion 35. The central portion 35 can be co-molded or insert molded with the flexible portion 33 of the base 34. The other portion 33 can be thought of as a more flexible portion and can be formed from any suitable material including, but not limited to, a PP-EPDM thermoplastic vulcanisate (TPV) or rubber. It is contemplated that a very flexible tub material can be utilized since the primary function of the tub 26 is to hold liquid. The connection of the structural support 80 to the tub 26 is illustrated as being close to the drive system components including the motor 40 and clutch 41.

Regardless of whether there is a central portion formed from a different material, it is contemplated that at least a portion of the base 34 may be formed from a flexible material and such flexible portion may be configured to move downwards to bear against the structural support 80 when liquid is located within the tub 26. When the tub 26 has a threshold amount of liquid in it, the flexible aspect allows the tub 26 to expand vertically under the weight of the liquid and to be more fully in contact with the structural support 80 such that the tub 26 is structurally supported. When liquid is drained from the tub 26, the tub 26 retracts and is decoupled from the structural support 80.

The tub 26 is configured such that when the base 34 is in the retracted position the base 34 does not bear on the structural support 80. In this manner, the tub 26 has a primary function of holding liquid and the more structural function has been removed and instead is provided by the structural support.

In other implementations in accordance with the present disclosure, the tub 26 expands vertically under the weight of the liquid but does not expand so far as to bear against the structural support 80.

FIG. 5 is a partially schematic cross-sectional view of a laundry treating appliance showing an alternative tub and suspension system according to another embodiment. The second embodiment is similar to the first embodiment; therefore, like parts will be identified with like numerals increased by 100, with it being understood that the description of the like parts of the first embodiment applies to the second embodiment, unless otherwise noted.

One difference is that the suspension system 136 couples the structural support 180 to a lower portion of the housing 114. In any of the described examples, the suspension system can couple the structural support to a lower portion of the housing. Additional differences are that the flexible portion of the base 134 of the tub 126 is corrugated and a portion of the base 134 is in contact with the structural support 180, when the tub 126 is in the retracted position. The corrugation allows the base 134 of the tub 126 to shift vertically under the weight of liquid during the cycle of operation so that the tub 126 comes into more intimate contact with the structural support 180. In this manner, the structural support 180 can support the extra weight within the tub 126. As the liquid is drained out of the tub 126, it will rise up and be more decoupled from the structural support 180.

While the remainder of the tub 126 may remain relatively rigid, a benefit of this approach is the opportunity to make the tub flexible so it can have a greater capacity. Regardless of whether the tub includes multiple materials and/or has a corrugated base section it is contemplated that the tub may be configured to move between a retracted position when the tub is empty and an expanded position, which is below the retracted position, when the tub contains liquid.

It will be understood that the structural support can be configured in any suitable manner. For example, FIG. 6 is a perspective view of a structural support 280 according to yet another embodiment. The third embodiment is similar to the first embodiment; therefore, like parts will be identified with like numerals increased by 200, with it being understood that the description of the like parts of the first embodiment applies to the third embodiment, unless otherwise noted.

One difference is that the structural support 280 is illustrated as a drive plate 282. The drive plate 282 may include a flat plate or can include an uneven plate. In the illustrated example, a portion of the plate is formed to complement the shape of the tub in its extended position. The suspension system can be operably coupled to the drive plate 282 at multiple locations including, corners 288. In the illustrated example, it is contemplated that the suspension system can operably couple to the drive plate 282 such that an attachment diameter is defined wherein the attachment diameter is substantially similar to a diameter of the tub (not shown). In this manner, very little additional space is taken up by the suspension system within the interior of the housing.

The various aspects described herein provide a variety of benefits including that a tub in which the structural component has been removed can be included in an appliance. A separate structural support can be utilized to support the tub and brace or otherwise buttress the tub and drive system components. Such aspects of the present disclosure prevent vibration transmission to the housing of the appliance and can result in reduced noise during operation. Further, aspects of the present disclosure can also allow for a larger capacity tub. Further, the tub can also be flexible, which can allow for the weight of the liquid in the tub to shift the tub vertically to be more fully in contact with the structural support. The structural function of the tub has been removed and replaced with a structural support that at least partially frames the flexible tub from the outside and provides structural support.

To the extent not already described, the different features and structures of the various embodiments is used in combination with each other as desired. That one feature may not be illustrated in all of the embodiments is not meant to be construed that it may not be, but is done for brevity of description. Thus, the various features of the different embodiments is mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

While the invention has been specifically described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention which is defined in the appended claims. 

What is claimed is:
 1. A laundry treating appliance for treating laundry according to an automatic cycle of operation, comprising: a cabinet defining an interior; a tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base; a structural support provided within the interior under at least a portion of the tub; and a suspension mounting the structural support to the cabinet.
 2. The laundry treating appliance of claim 1 wherein the suspension comprises a plurality of suspension rods coupling the structural support to an upper portion of the cabinet.
 3. The laundry treating appliance of claim 1 wherein the structural support has four arms and the suspension mounts each arm to a corner of the cabinet.
 4. The laundry treating appliance of claim 1 wherein the suspension couples the structural support to a lower portion of the cabinet.
 5. The laundry treating appliance of claim 1 wherein the portion of the base of the tub mounted to the structural support is formed from one of polypropylene or aluminum.
 6. The laundry treating appliance of claim 1 wherein the base of the tub further comprises a central portion that mounts to the structural support.
 7. The laundry treating appliance of claim 6 wherein the central portion is formed from one of polypropylene or aluminum.
 8. The laundry treating appliance of claim 6 wherein the central portion is co-molded or insert molded with the flexible portion of the base.
 9. The laundry treating appliance of claim 1 wherein at least a portion of the base of the tub is formed from a flexible material and such flexible portion is configured to move downwards to bear against the structural support when liquid is located within the tub
 10. The laundry treating appliance of claim 9 wherein the flexible portion of the base is formed from a PP-EPDM thermoplastic vulcanisate (TPV) or rubber.
 11. The laundry treating appliance of claim 9 wherein the flexible portion of the base is corrugated.
 12. The laundry treating appliance of claim 1 wherein the structural support is a drive plate.
 13. The laundry treating appliance of claim 12 wherein the suspension operably couples to the drive plate such that an attachment diameter is defined wherein the attachment diameter is substantially similar to a diameter of the tub.
 14. The laundry treating appliance of claim 1, further comprising a wash basket located within the tub, and defining a treating chamber for receiving the laundry, with the wash basket being rotatable about a vertical axis of rotation.
 15. The laundry treating appliance of claim 14 wherein the tub is free of ribbing.
 16. A laundry treating appliance for treating laundry according to an automatic cycle of operation, comprising: a cabinet defining an interior; a tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base; a structural support provided within the interior beneath the tub; and a suspension system coupling the structural support to the cabinet; and wherein at least a portion of the base of the tub is formed from a flexible material and such flexible portion is configured to move downwards under a weight of liquid located therein.
 17. The laundry treating appliance of claim 16 wherein the flexible portion of the tub has substantially the same flexibility as a sidewall of the tub.
 18. The laundry treating appliance of claim 16 wherein the flexible portion of the tub is configured to move downwards under the weight of the liquid to bear against the structural support.
 19. The laundry treating appliance of claim 16 wherein the structural support comprises a plate or a set of arms.
 20. The laundry treating appliance of claim 16 wherein the suspension system comprises a plurality of suspension rods coupling the plate or the set of arms to the cabinet.
 21. A laundry treating appliance for treating laundry according to an automatic cycle of operation, comprising: a cabinet defining an interior; and a tub located within the interior and having a peripheral wall with an upper portion and a bottom end closed by a base; and a structural support separate from the tub and provided within the interior adjacent a base of the tub and where the structural support is mounted to the cabinet via a suspension system.
 22. The laundry treating appliance of claim 21 wherein at least a portion of the base is configured to move between a retracted position when the tub is empty and an expanded position, which is below the retracted position, when the tub contains liquid and when the at least a portion of the base is in the retracted position the at least a portion of the base does not bear on the structural support. 